Coupling surgical instruments to robotic surgical systems

Abstract

A robotic surgical system includes a surgical instrument, a robotic arm, and a coupler assembly. The surgical instrument defines a longitudinal axis therethrough and supports an end effector on a free distal end portion of the surgical instrument. The robotic arm includes segments that are movably coupled together by joints. A first joint has at least two degrees of freedom for positioning the surgical instrument relative to a patient. The coupler assembly removably couples the surgical instrument to the robotic arm. The coupler assembly is positioned to enable the surgical instrument to rotate about the longitudinal axis and relative to the robotic arm.

What is claimed: 
     
       1. A robotic surgical system, comprising:
 at least one surgical instrument having an instrument drive unit supported on a proximal end portion thereof, an elongated shaft that extends distally from the instrument drive unit, and an end effector secured to a distal end portion of the elongated shaft and operably connected to the instrument drive unit by a connector member for operating the end effector, the at least one surgical instrument defining a longitudinal axis that extends therethrough from the instrument drive unit to the end effector; 
 a robotic arm including at least three segments that are movably coupled together by at least three joints, wherein at least a first joint of the at least three joints has at least two degrees of freedom such that the first joint can rotate in different directions about orthogonal axes defined through the first joint, at least two segments of the at least three segments and the at least three joints are movable to position the end effector relative to a patient; and 
 a mounting member supported by the robotic arm and configured to be removably coupled to the at least one surgical instrument by a coupler assembly, the coupler assembly including:
 a support member secured to the mounting member, the support member being tubular and having at least one first mating feature projecting radially outwardly for securing the at least one surgical instrument to the mounting member; and 
 a rotation hub secured to the at least one surgical instrument, the rotation hub defining at least one diagonal slot extending proximally from a distal edge of the rotation hub, and is configured to receive the corresponding at least one first mating feature, whereby the rotation hub is selectively connectable to the support member via a bayonet-type connection, 
 
 wherein, the at least one surgical instrument is rotatable about the longitudinal axis and relative to the mounting member when the at least one surgical instrument is coupled to the coupler assembly. 
 
     
     
       2. The robotic surgical system of  claim 1 , wherein the coupler assembly defines a throughbore that facilitates passage of the elongated shaft of the at least one surgical instrument through the mounting member. 
     
     
       3. The robotic surgical system of  claim 2 , wherein the support member of the coupler assembly is a first hub of the coupler assembly, wherein the first hub includes the at least one first mating feature, and wherein the first hub is stationary within the mounting member. 
     
     
       4. The robotic surgical system of  claim 3 , wherein the at least one first mating feature includes three bosses disposed radially about the first hub at equidistant radial locations. 
     
     
       5. The robotic surgical system of  claim 4 , wherein the rotation hub of the coupler assembly is a second hub of the coupler assembly, wherein the at least one diagonal slot defines at least one second mating feature, wherein the at least one second mating feature includes a second mating feature corresponding to each boss of the first hub. 
     
     
       6. A robotic surgical system, comprising:
 a surgical instrument having a proximal end portion, an elongated shaft that extends distally from the proximal end portion and defines a longitudinal axis therethrough, and an end effector supported on a free distal end portion of the surgical instrument and secured to a distal end portion of the elongated shaft, the end effector including a first jaw member and a second jaw member; 
 a robotic arm including at least three segments that are movably coupled together by at least three joints, wherein at least a first joint of the at least three joints has at least two degrees of freedom, and wherein at least two segments of the at least three segments and the at least three joints cooperate to position the surgical instrument relative to a patient; and 
 a coupler assembly that removably couples the surgical instrument to the robotic arm, the coupler assembly including:
 a support member secured to a mounting member, the support member being tubular and having at least one first mating feature projecting radially outwardly for securing the at least one surgical instrument to the mounting member; and 
 a rotation hub secured to the at least one surgical instrument, the rotation hub defining at least one diagonal slot extending proximally from a distal edge of the rotation hub, wherein the at least one each diagonal slot is configured to receive the at least one first mating feature, whereby the rotation hub is selectively connectable to the support member via a bayonet-type connection, 
 
 whereby the surgical instrument is rotatable about the longitudinal axis defined through the elongated shaft and relative to robotic arm. 
 
     
     
       7. The robotic surgical system of  claim 6 , wherein the at least one first mating feature includes a boss. 
     
     
       8. The robotic surgical system of  claim 7 , wherein the at least one first mating feature includes three bosses disposed radially about the first hub at equidistant radial locations. 
     
     
       9. The robotic surgical system of  claim 8 , wherein the coupler assembly includes a prong and an outer flange, the outer flange defining a second slot positioned to receive the prong. 
     
     
       10. The robotic surgical system of  claim 9 , wherein the outer flange extends radially outward from an outer surface of the coupler assembly.